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SINGLE SERVING AUTOMATIC POD MACHINE NEWCO ENTERPRISES INC, 3650 NEW TOWN BLVD. SAINT CHARLES, MO 63301 1-800-325-7867 FAX 1-636-925-0029 Features/ Specifications • • AUTOMATIC POD REMOVAL LARGE POD WASTE TRAY / THRU COUNTER OPTION • ADJUSTABLE DRINK STRENGTH • ADJUSTABLE DRINK VOLUME 1 • 16 GRAM POD CAPACITY • REMOVABLE DRIP TRAY TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................... 3 NEWCO PRODUCT WARRANTY .................................................................................. 4 MACHINE SET-UP......................................................................................................... 5 MACHINE OPERATION ................................................................................................. 6 MACHINE PROGRAMMING AND CALIBRATION......................................................... 7 SERVICING THE MACHINE ......................................................................................... 10 TANK REMOVAL ......................................................................................................... 11 POD BREWING MECHANISM ..................................................................................... 12 ELECTRICAL COMPONENTS ..................................................................................... 16 ERROR MESSAGES .................................................................................................... 17 FLOW ADJUSTMENT CONTROL ................................................................................ 18 WIRING DIAGRAM ....................................................................................................... 19 2 SPECIFICATIONS TANK WATTAGES US 1700W 120V- CANADA 1400W 120V- INTERNATIONAL 1700W 220V TANK CAPACITY-1 US GALLON DRIP TRAY CAPACITY 8 OUNCES POD WASTE TRAY CAPACITY 80 PODS-USE WASTE TRAY PN 780306 FOR THRU-COUNTER USE UP TO 16 OZ CUP SIZE SHIPPING WT-APPROX 35 LBS 3 NEWCO PRODUCT WARRANTY Newco warrants equipment manufactured by it for 1 Year Parts & Labor These warranty periods run from the date of installation Newco warrants that the equipment manufactured by it will be commercially free of defects in material and workmanship existing at the time of manufacture and appearing within the applicable warranty period. This warranty does not apply to any equipment, component or part that was not manufactured by Newco or that, in Newco’s judgment, has been affected by misuse, neglect, alteration, improper installation or operation, improper maintenance or repair, damage or casualty. This warranty is conditioned on the Buyer 1) giving Newco prompt notice of any claim to be made under this warranty by telephone at (800) 556-3926 or by writing to PO Box 852, Saint Charles, MO 63302; 2) if requested by Newco, shipping the defective equipment prepaid to an authorized Newco service location; and 3) receiving prior authorization from Newco that the defective equipment is under warranty. THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The agents, dealers or employees of Newco are not authorized to make modifications to this warranty or to make additional warranties that are binding on Newco. Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not be relied upon. If Newco determines in its sole discretion that the equipment does not conform to the warranty, Newco, at its exclusive option while the equipment is under warranty, shall either 1) provide at no charge replacement parts and/or labor (during the applicable parts and labor warranty periods specified above) to repair the defective components, provided that this repair is done by a Newco Authorized Service Representative; or 2) shall replace the equipment or refund the purchase price for the equipment. THE BUYER’S REMEDY AGAINST NEWCO FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE OF THIS EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR OTHERWISE, SHALL BE LIMITED, AT NEWCO’S SOLE OPTION AS SPECIFIED HEREIN, TO REPAIR, REPLACEMENT OR REFUND. In no event shall Newco be liable for any other damage or loss, including, but not limited to, lost profits, lost sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities or services, or any other special, incidental or consequential damages. 4 MACHINE SET-UP NOTE: The FRESH CUP machine weighs approximately 35 LBS. Use CAUTION when unpacking and lifting machine. LIFT MACHINE FROM MACHINE BOTTOM ONLY. DO NOT MOVE MACHINE UNLESS THE HOT WATER TANK IS DRAINED AND EMPTY. 1. Open and install the drip tray grill and place drip tray into pod tray 2. Connect water fitting with strainer on the rear of machine under the power switch. Plumber's Installation Instructions 1) Brewer must be installed to comply with all applicable federal, state and local plumbing codes and ordinances. 2) Plumb brewer in to water supply using 1/4 inch copper tubing. Flush water line before installing brewer to remove sediment. Brewer should be connected to COLD WATER LINE for best operation. 3) Water pressure should be at least 20 lbs. For less than a 25 ft run, use 1/4" tubing and connect to 1/2" or larger water line. The inlet water fitting on the back of the brewer is a 1/4" flare fitting. It may be necessary to remove the plumbing cover box on the rear of brewer to access water connection point. 4) If installed with saddle valve, the valve should have a minimum of 1/8" porthole for up to 25 ft run, and 5/16" porthole for over 25 ft runs. 5) Turn on water supply and check for leaks. WARNING: - Read and follow installation instructions before plugging or wiring in machine to electrical circuit. Warranty will be void if machine is connected to any voltage other than that specified on the serial tag. Turn the power switch to the “OFF “ position and plug the machine into a properly installed and grounded electrical circuit. Turn on power switch to start the initial WATER FILL CYCLE. When tank is filled, the heater circuit will turn on-allow up to 20 min for the tank to reach brewing temperature. Machine is now ready for programming or operation. 5 MACHINE OPERATION BREWING INDICATOR LIGHT DRAWER OPEN BUTTON READY TO BREW INDICATOR LIGHT • • • • • • PUSH & HOLD FOR HOT WATER DISPENSE WHEN DRAWER IS CLOSED PROGRAMMABLE BREW BUTTONS (CUP STRENGTH OR CUP SIZE, TEA, ETC PUSH TO RETURN BREW MECHANISM TO HOME POSITION WHEN DRAWER IS OPEN TEMPERATURE RANGE IS 170-205 DEGREES POWER SAVE OR POWER FEATURE AVAILABLE BEEPER VOLUME CAN BE ADJUSTED OR BEEPER CAN BE SHUT OFF AIR PUMP POD DRYING TIME & PUMP STRENGTH CAN BE ADJUSTED POD COUNT TO EMPTY POD WASTE BIN AJDUSTABLE OR CAN BE TURNED OFF IF USING THROUGH THE COUNTER WASTE BIN COFFEE OR TEA PRE-INFUSTION, BREW TIME & BREW VOLUME ADJUSTABLE FOR EACH OF 3 CUSTOMIZABLE DISPENSE BUTTONS BREW OPERATION 1. 2. 3. 4. PLACE CUP UNDER BREW NOZZLE ON DRIP TRAY PRESS THE DRAWER OPEN BUTTON UNWRAP THE POD & PLACE IN CENTER OF BREW CHAMBER PRESS THE DESIRED BREW BUTTON-DRAWER WILL CLOSE & BREW CYCLE WILL START 5. ONCE THE POD DRYING CYCLE IS COMPLETE, THE POD WILL EJECT & THE CUP CAN BE REMOVED 6 MACHINE PROGRAMMING AND CALIBRATION NOTE: THE MACHINE HAS BEEN CALIBRATED AT THE FACTORY AND HAS BEEN ADJUSTED TO BREW INTO AN 8 OUNCE CUP WITH APPROX 7 OUNCES OF COFFEE FOR BREW STRENGTHS OF MILD, REGULAR AND BOLD. NO FURTHER ADJUSTMENTS ARE NECESSARY IF THE FACTORY DEFAULTS ARE USED. A B C D RESET Fig 1: Fresh Cup Keys The Fresh Cup pod brewer has a menu that consist of scrolling menu entries that can be scanned through backward and forward using button A and button B (see Fig 1). To enter a programming record, press and hold the Reset Key when powering up machine (see Fig 1) then use button A and button B (see Fig 1) to change the entry. Pressing the Reset key (see Fig 1) will exit the entry, saving the entire Parameter structure to memory upon exiting the programming menu using the END entry. There are nine entries on the Main menu and four on one sub menu, which is accessed through the BUTTON SET UP entry. The current entries in the Main menu are as follows: TEMPERATURE: In this entry the user may set the tank temperature in the range of 170 to 205 degrees Fahrenheit with the default at 200 degrees F. Pressing button D (see Fig 1) will toggle the display so the user may view the real tank temperature. The real temperature display has all three decimal points illuminated. Pressing button D (see Fig 1) again will switch the display back to show the current set point. As with most of the entries, button A and button B (see Fig 1) will change the set point, incrementing or decrementing by one. Pressing Reset key (see Fig 1) will exit. POWER SAVE: This entry allows the user to select the Power Save mode. Use button A and button B (see Fig 1) to change the entry then press the Reset key to exit. Off (default) – Turns Power Save function off. Prt – Partial Power Save Mode. After the user selectable time out the tank temperature set point is set to 180 until a key is pressed. When this mode is selected the right most decimal point in the display is on. FuL – Full Power Save Mode. After the user selectable time out the tank heater is disabled until a key is pressed. When this mode is selected the left most decimal point in the display is on. POWER SAVE TIME: This entry will not be displayed if the Power Save function has been turned off. This entry sets the time the machine will operate normally until the power save function is activated. The user can choose 1 through 4 hours in 1-hour increments with the default set to 4 hours. As with most of the entries, button A and button B (see Fig 1) will change the time, incrementing or decrementing by one. Pressing Reset key (see Fig 1) will exit. 7 PROGRAMMING AND CALIBRATION CONT’D BEEPER VOLUME: The range is from 1 to 24. The default is 13. AIR PUMP SPEED: In this entry the user may set the air pump strength in the range of 5 to 10 strength with the default at 9. As with most of the entries button A and button B (see Fig 1) will change the Air Pump Strength, incrementing or decrementing by one. Pressing Reset (see Fig 1) key will exit. AIR PUMP TIME: In this entry the user may set the air pump time in the range of 2 to 10 seconds with the default at 5. As with most of the entries button A and button B (see Fig 1) will change the Air Pump Time, incrementing or decrementing by one. Pressing Reset (see Fig 1) key will exit. POD COUNT: In this entry the user may set the number of pods the brewer will hold before signaling that the bin is full. The range is 10 to 100 pods, with the default at 40. Setting the pod count under 10 turns off the count so the bin full alarm will never go off. As with most of the entries button A and button B (see Fig 1) will change the Pod Count threshold, incrementing or decrementing by one. Pressing Reset key (see Fig 1) will exit. CALIBRATION: This entry shows the amount of water the brewer dispenses in 30 seconds with no pauses. To run calibration, place a container able to hold at least 10 oz preferably greater. Press button D (see Fig 1) and the brewer will enter a brew cycle. The door will open to allow the user to place a beverage pod in the drawer. After the pod has been placed press the button D button (see Fig 1) again to start the brew cycle. After the cycle has completed, measure the amount of water dispensed and adjust the Calibration number shown in tenths of an ounce to match the amount dispensed by using button A and button B (see Fig 1) to increment or decrement by one. Press the Reset key (see Fig 1) to advance to the brew button programming selections. Range for the calibration volume is 10 to 320 tenths of an ounce. The default is 100 tenths of an ounce. BUTTON SET UP: This entry takes the user into a sub menu to program the parameters unique to each key. When this entry is accessed the display will change to SELECT BUTTON indicating that the user should press the brew key (button B, C or D (see Fig 1)) to be programmed. When a brew key is selected the display will show the first entry in the Button Set up sub menu, PRE-INFUSION. While SELECT BUTTON is displayed the user may exit back to the Main menu by pressing the Reset key (see Fig 1). With these four entries in the BUTTON SET UP sub menu: PRE-INFUSION: This entry sets the time of the pre-infusion pulse of water in tenths of a second. Range is 1 to 30, the default is 15 tenths of a seconds. BREW VOLUME: This entry sets the volume in tenths of an ounce for this key to dispense. The Range is from 40 to 140 tenths of an ounce with the default set to 70 tenths of an ounce BREW TIME: This entry sets the brew time in seconds for a 10-ounce cup of coffee with on/off pulses. The range is from 30 to 99 seconds with the default being 35 seconds. RETURN: Exit to Main Programming Menu. FILTER SELECT: This entry allows the user to select the filter size for the filter used on the inlet for the water. Choices include OFF, 500 GAL, 1000 GAL and 1500 GAL. These set the counter for the filter warning. Whenever water is dispensed the counter is incremented to 8 account for the water dispensed. When the counter is above 90% of the capacity of the chosen filter a warning message, “REPLACE WATER FILTER”, is displayed in place of the “READY” message. To reset the counter the user must enter the programming menu and enter the RESET FILTER entry described below. The following entries are only shown when a filter is selected. If the filter selection is OFF then following entries are not available. Press the Reset key (see Fig 1) to leave the entry and return to the Main Programming menu. FILTER REMAINING: This entry scrolls the number of Gallons left before the filter should be replaced. Press the Reset key (see Fig 1) to leave the entry and return to the Main Programming menu. RESET FILTER: When in this entry the message “PRESS OPEN TO RESET’. Press the Open Door key will reset the Filter Use counter to the value chosen in the FILTER SELECT entry above. Press the Reset key (see Fig 1) to leave the entry and return to the Main Programming menu. END – Exit to Main and save parameters. DRAINING THE HOT WATER TANK THE DRAIN TUBE IS CLIPPED TO THE TANK PLATE IN FRONT OF THE TANK. THE HOT WATER TANK CAN BE DRAINED FROM THE FRONT OF THE MACHINE – UNPLUG MACHINE FROM POWER SOURCE . REMOVE POD WASTE TRAY. CAUTION-UNLESS THE TANK IS LEFT TO COOL THE WATER IS EXTREMELY HOT AND CAN CUASE HARMFUL BURNS. REPLACE DRAIN PLUG, ENSURE HOSE CLAMP IS TIGHT AND REPOSITION DRAIN HOSE BEFORE RE-FILLING THE HOT WATER TANK. 9 SERVICING THE MACHINE The Fresh Cup machine has a modular Water Tank Assembly and Brew Mechanism. These assemblies can be easily removed from the machine by removing or loosening Machine nuts as noted in drawings below: BREW MECHANISM ACCESS SCREWS (VIEW FROM BOTTOM FRONT OF MACHINE) REMOVE BRASS KNURLED NUTS (2) NOTE: TO REMOVE BREW MECHANISM, UNSNAP WATER & HARNESS FITTINGS LOOSEN ACORN NUTS (4) 10 TANK REMOVAL & TRANSFORMER ACCESS REMOVE (2) 8-32 NUTS ON SIDE WALL REMOVE (1) 8-32 NUT ON PUMP BRACKET 11 LOOSEN BUT DO NOT REMOVE THESE 2 SCREWS THEN LIFT & PULL CONTROL BOARD & BRACKET OUT OF MACHINE TO ACCESS TRANSFORMER POD BREWING MECHANISM BREW MECH ASS'Y 780234 (SPECIFY POD SIZE 56MM OR 61MM) 4 1 3 2 5 6 1 7 2 12 POD BREWING MECHANISM CONT’D ITEM # NEWCO PN 1 2 3 4 5 5 6 7 780230 780231 780257 773246 780262 780314 780264 780317 DESCRIPTION BREW MECH MOTOR DELTROL SOLENOID UPPER BREW CHAMBER U-CUP SEAL RING LOWER BREW CHAMBER 61MM LOWER BREW CHAMBER 56MM O-RING .489 X .629 X .070 POD KICKER ASS’Y QTY/EA 2 2 1 1 1* 1* 1 1 *MACHINE IS ORDERED FOR 56MM OR 61MM POD SIZE 13 780234 TANK ASS’Y 10 1 2 9 3 8 7 6 4 5 14 780234 TANK ASS’Y CONT’D ITEM # NEWCO PN 1 2 3 4 5 6 7 8 9 10 110958 111593 706341 781772 780253 773056 108022 151677 110051 704166-10 DESCRIPTION RELAY, 12 VDC SPST 30A HI-LIMIT THERMOSTAT PUMP ASS’Y-120 VOLT PUMP ASS’Y W/ELBOW PUNCHED TANK W/STUD AIR PUMP, POD LIQUID LEVEL PROBE DUAL TEMP THERM PROBE ELBOW ¼ TUBE X 1/8 NPT TANK HEATING ELEMENT 15 QTY/EA 1 1 1 1 1 1 1 1 1 1 ELECTRICAL COMPONENTS 1 2 3 5 4 16 ELECTRICAL COMPONENTS CONT’D ITEM # NEWCO PN 1 2 3 4 5 780225 110626 780365 105115 780224 DESCRIPTION CONTROL BOARD SWITCH, DPST, ON/OFF VALVE ASSY., FRESH CUP TRANSFORMER 120VAC-24VAC DISPLAY BOARD QTY/EA 1 1 1 1 1 ERROR MESSAGES Message - "THERMISTOR ERROR" THERMISTOR IS OPEN OR SHORTED-REPLACE PN 151677 Message - "HIGH TEMP ERROR" RAPID TEMPERATURE RISE-HEATER ON WITH LOW WATER LEVEL-CHECK FILL VALVE OR WATER SUPPLY LINE Message - "UPPER/LOWER MOTOR ERROR" BREW CHAMBER DRIVE MOTOR ERROR-CHECK FOR JAM OR OBSTRUCTION IN BREW CHAMBER Message - "BOARD ERROR" CONTROL BOARD WRITE ERROR-REPLACE BOARD IF MESSAGE DOES NOT CLEAR PN 780225 Message - "FILL TIMEOUT ERROR" WATER NOT REACHING LEVEL PROBE-CHECK WATER SUPPLY OR CHECK FOR WATER LEAK Message - "HEATER TIMEOUT ERROR" WATER NOT HEATED DURING TIMEOUT PERIOD-CHECK HEATER RELAY PN 110958 OR HEATING ELEMENT PN 704166-10(1700W US) OR 704161-10 (1400W CANADA) OR HI-LIMIT THERMOSTAT PN 111593 17 FLOW ADJUSTMENT CONTROL VIEW FROM TOP OF MACHINE COVER REMOVED ONLY USED DURING MACHINE CALIBRATION ! ! CALIBRATION PUMP FLOW ADJUSTMENT CLOCKWISE DECREASE FLOW COUNTER CLOCKWISE INCREASE FLOW 18 WIRING DIAGRAM 780225 SWITCH/DISPLAY BOARD BK RD WASTE BIN REED SWITCH CN8 CN2 PROGRAMMING HEADER CN3 2 1 4 3 BK CN1 RD BK RD GY LOWER SOLENOID UPPER SOLENOID 12 VDC 12 VDC BK RD CN6 2 1 GY 4 3 780224 24 VDC BK BR YL BK WH CONTROL BOARD UPPER DRIVE MOTOR BK RD RD BK +- RD BL CN7 7 6 5 4 3 2 1 RD GY -+ OR BR WH GY BK BK/WH BK OR AIR PUMP 12 VDC 4321 321 RD - COFFEE PUMP 120 VAC 8765 CN5 12 VDC RD BR CN4 654 HOT + WATER PUMP 24 VDC BK/WH BK GY GY LOWER DRIVE MOTOR BR CENTER TAP BK/WH LEDs + 12/24 VAC BR - TRANS FORMER BK GY 120 VAC YL RD VIO/BK RD BK 14 13 12 11 10 9 8 BK BK WH RD DUAL THERMISTOR TANK HEATER ELEMENT WH HEATER RELAY 12 VDC COIL + GY VIO/BK VIO/BK HI-LIMIT THERMOSTAT TANK GND LIQUID LEVEL PROBE VIO/BK DPST SWITCH VIO/WH BK WH VIO/BK HOT WATER TANK GN WH FILL SOLENOID BK 120 VAC WH BK POWER CORD 19